Design considerations of high-voltage motor control system
In the design of modern robots, any movement of the head, neck, and limbs requires the support of various motors, such as traditional rotary motors, stepper motors, linear motors, and other special motors, but the driving and control of these motors Requirements are different, how to achieve precise control solutions for various motors? How to control them with the lowest power consumption? It is often a challenge for designers. This article will discuss in detail which issues should be paid attention to when implementing each core subsystem of the high-voltage motor control system.
High-voltage alternating current (HVAC) motors, industrial inverters, or high-voltage permanent magnet brushless motors are a few examples of high-voltage systems, which are typically classified according to their horsepower. Although it is still the most common, other types of motors have also appeared, such as linear motors and gear head motors implemented with various exciters embedded. Digital motor control solutions allow precise control of the position, speed and torque of these mechanical drive mechanisms. The capacity of MOSFETs in such large mechanical drive mechanisms usually exceeds 600V.
For example, TI has a gate drive solution TPS2829, an in-phase high-speed MOSFET driver. When combined with the TLV3501 comparator in the feedback loop, the gates in these systems can be digitally controlled. In addition, TI's MOSFET drivers (such as UCC37321 or UCC37323) can directly drive small motors or drive power devices such as MOSFETs or IGBTs.
Main design considerations of high-voltage motor control system
The core subsystem of the high-voltage motor control system includes: controller, isolation, controller interface and motion feedback.
Controller: TI also provides a series of control processor solutions, from ultra-low-power MSP430 microcontrollers to TMS470 ARM7-based processors and C2000 digital signal controllers (DSC). Proper controller can optimize motor drive efficiency, improve reliability and reduce overall system cost. The C2000 controller's 32-bit DSP-level performance and on-chip peripherals optimized for motor control allow users to easily implement advanced algorithms, such as sensorless vector control of three-phase motors. The C2000 series controllers (from the low-cost F28016 to the industry's first floating-point DSC TMS320F28335) remain software compatible.
Isolation: TI's digital isolators have logic input and output buffers that use silicon dioxide for isolation, providing 4kV isolation. When used in conjunction with isolated power supplies, these devices can block high voltages, isolate ground, and prevent noise current from entering the local ground, as well as interfere with or damage sensitive circuits.
Controller interface: RS-232 or RS-422 is sufficient for many systems. RS-485 signaling may be bundled with some protocols, such as Profibus, Interbus, Modbus or BACnet, each for the specific needs of end users. Sometimes, Controller Area Network (CAN) or EtherNet / IP (Industrial Protocol) are used to meet networking requirements. M-LVDS is an alternative that can provide lower power consumption.
Motion feedback using external circuits: The isolated Delta-Sigma modulator (AMC1203 / AMC1210) is ideal for shunt measurement to smooth out glitches and increase current feedback resolution. In addition, INA19x (x = 3 to 8) and INA20x (x = 1 to 9) provide a wide common-mode voltage for low-end and high-end current shunt monitoring.
Hall effect or magnetic sensors are usually more efficient when measuring currents above 10A, and they can inherently provide isolation capabilities. ADS1204, ADS1205 and ADS1208 are three recommended devices. To connect the ± 10V (20Vpp) signal to an ADC using a 3.3V or 5V power supply, an INA159 level difference amplifier can be used. ADCs like ADS7861 / ADS7864 or ADS8361 / ADS8364 can provide simultaneous current sampling of 4 channels or 6 channels.
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